Control system



Feb. 25., 1936. F, KQVALSKY 2,032,176

CONTROL SYSTEM Filed April l2, 1932 2 Sheets-Sheet 2 WITNESSES: y INVENTOR a A 'Jbhfqa/vrxam/ y Patented ret. 2s, 193e l UNITEDv STATES PATENT GFFICE CONTROL SYSTEM Application April 12, 1932, Serial No. 604,699

1 Claim.

My invention relates generally to control systems and more particularly. to control systems that may be utilized for operating electric motors.

An object of my invention is the provision of a control system of the class indicated that shall be simple and reliable in operation and be readily and economically manufactured and installed.

Another object ofmy invention is to provide for regulating the amount of current passing between the anode and the cathode of a grid-glow tube by utilizing an improved form of bridge phase-shifting circuit.

It is also an object of my invention to provide for automatically and gradually accelerating an velectric motor from rest to any predetermined selected speed.

A further object of my invention is to provide for varying the rate of acceleration of an electric motor.

A still further object of my invention is to provide for momentarily giving a relatively high starting torque.

Further lobjects and a fuller understanding oi my invention may be had by referring to the following description taken in connection with the accompanying drawings, in which:

Figure 1 is a diagrammatic view of a control system embodying the features of my invention,

Fig. 2 is a graphical representation of the electrical characteristics of a power grid-glow tube in which the shaded portion indicates the quantity of current ilowing between the anode and the cathode at a definite phase angle between the potential of the anode and the grid.

Fig. 3 is a similar graphical representation of the electrical characteristics of a power gridglow tube in which the relatively small shaded portion represents the quantity of current flowing between the anode and the cathode at a larger phase angle than that shown in Fig. 2,

Fig. 4 is a vector representation of the phase angle and magnitude of the grid potential of a power grid-glow tube with respect to its anode potential.

Fig. 5 is a diagrammatic view of a control system embodying a modified form of my invention wherein means are provided for automatically and gradually accelerating the motor from rest to any predetermined selected speed, and

Fig. 6 is a diagrammatic view showing a part only of the bridge phase-shifting circuit shown in Fig. l, together with means for operating the phase shifting circuit in accordance with the tension of material as it is being wound upon a reel.

With particular reference to Fig. l, my invention comprises, in general, a motor i0 having a field winding il, a transformer 9 having a primary winding i2, and a plurality of secondary windings i6, 'I1 and i8, a' pair of asymmetric units 4| and 42 for supplying unidirectional current to the eld winding ii, two power gridglow tubes 2l and 3|, a relay 43 for connecting the power grid-glow tubes 21 and 3i in circuit relation with the armature of the motor i0 and the secondary winding i8, a'set of push buttons 44 and 45 for operating the relay 43, and a bridge phase-shifting circuit i3 for shifting the phase of the grid potential of the power grid-glow tubes 21 and 3i relatively to their anode potentials.

The field winding Il of the motor i 0 is disposed to be energized with unidirectional current provided by the pair of asymmetric units 4i and '42 which are connected across the terminals 53 'I'he winding i9 having a mid-tap 54 is arranged to be connected in circuit relation with the armature of the motor i6 and the power grid-glow tubes 2l and 3| by means of the relay 43. The secondary transformer winding i'i provides energization for electrically heating the cathodes 3D and 340i the power grid-glow tubes. The secondary winding I6 having a mid-tap i5 comprises'a part of the bridge phase-shifting circuit I3 for varying the phase relation and the mag nitude of thegrid potential relatively to the anode potential of the power grid-glow tubes.

The power grid-glow tubes 21 and 3i are essentially grid-controlled gaseous discharge tubes and comprise, respectively, anodes 28 and 32, cathodes 30 and 34, which are generally called the conducting electrodes, and grids 29 and 33, which are sometimes referred to as control electrodes. Inasmuch as power grid-glow tubes have the property oi rectifying alternating current, I provide for utilizing two in order to give doublewave rectification. However, it will be readily understood that my invention is operable by using only one power grid-glow tube.

The power grid-glow tubes are preferably of the well known type wherein the cathode comprises a filament surrounded by an inert gas. The filament when electrically heated by a suitable source of current, such as the secondary transformer winding i1, liberates primary elecexercising any further control over the arc. Con-- `trons which are necessary for the functioning of produce both new electrons and positive ions. AsA

, definite critical grid potential at which ionization On the contrary, if the potential of the grid rises 'between the anode and the cathode, but is not -ing an alternating current voltage to the anode passing between theanode and the cathode.

'employ the phase-shitting" method. However.

the magnitude of the grid potential relative to a power grid-glow tube. When a potential dif- -the anode potential comprises a capacitor 31, a ference is applied between the anode and cathode', the anode being at a high potential, the liberated primary electrons move towards the anode. As these primary electrons acquire suiiicient velocity, they collide with the molecules of the gas and magnetic core 39, both connected in series circuit relation with the secondary winding I6 of the transformer 9, and a Igrid resistor 35 connected between the mid-tap I5 of the secondary winding I6 and a junction point I9 of the capacitor 31 and the control winding 38. As illustrated, the grid resistor 35 has a mid-tap 36 and comprises two sections. The left-hand section is connected in parallel circuit relation with the grid 33 and the cathode 34 of the power grid-glow tube 3I, and the right-hand section is connected in parallel circuit relation with the grid 29 and the cathode 30 of the power grid-glow tube 21. Hence, by reason of the fact that the grids of the power grid-glow tubes and their respective` sections of the grid resistor 35 are connected in the primary electrons, as well-as the newly formed electrons, move towards the anode, they will have to pass the` grid structure. The grid .may be charged either to a positive or a negative potential and, therefore, helps' to either accelerate or retard the movements of the passing electrons. Hence; the action of the grid is such as tocontrol the value of the anode-cathode potential at which I the gas becomes ionized, or at which an arc is formed for the passage of a current between the anode and the cathode. .For convenience, and in accordance with the accepted engineering par'- lance, the potential of the grid will hereinafter be considered with reference to the potential of the anode. For a given anode potential, there is a magnitude of the grid potentials relative to the anode potentials change in accordance with variations oi the phase relation and magnitude of their respective sections of the grid resistor 35 by the bridge phase-shifting circuit I3.

Consider Figs. 2 and 3, and 4 which represent by curves and vector diagram respectively, how the grid potential relative to the anode potential varies the amount of current passing between the occurs, thus allowing the power grid-glow tube to pass current in the form of a glow discharge (see Figs. 2 and 3). If the potential of the grid is below this critical grid potential, no dischargeoccurs, and accordingly, substantially no `current pases between the anode and the cathode.

above the critical grid potential,` even for a momentary period, a discharge immediately occurs and current of relativelylarge value passes between the anode and the cathode. After the discharge o'r arc has started, however, the grid is surrounded by a space charge which thereby prevents it from wave or curve represents the anode. potential and the -lower sinusoidal wave orV curve substantially represents the grid potential, and the concave- So long as'the grid potential is below the value of the critical grid potential, no arc between the `anode and the cathode is formed for passing current. However, as soon as the value of the grid potential rises to, or above, the critical grid potential, ionization occurs, at lthe point where the grid potential curve intersects the critical grid potential curve and an arc is formed for passing current between the anode and the cathode for sequently, the grid of a grid-glow tube is eective only in either preventing, or initiating, an arc effective in extinguishing or controlling the arc after it is once started. However, the grid can regain control land thus prevent the arc from starting again, if the iiow of current between the anode and the cathode ceases momentarily thus allowing the gas to deionize. Therefore, by apply- 2 and 3, the shaded portions represent, respectively, the quantity of current passing between the anode and the cathode during each half and the cathode, the gridhas an opportunity o cycle for the illustrated phase angle displaceregaining control once each cycle and can` delay the starting of an arc for as long a time during the cycle as the potential of the grid is below the critical grid potential. For the control of grid-glow tubes, two fundamental methodswell known in the art. are available. In theiirst or magnitude method, the phase relation of the grid potential relative to the anode potential remains fixed, but the magnitude oi the grid potential is varied relatively. to the anode potential for controlling the current. passing between the anode and theoathcde. In the second or "phase-shitting". methodthe magnitude of the grid potential remains substantially xed relative to the anode potential. but the phase relation o! the grid potential relative to the anode potential is shifted -ior controlling the current of current passing between the anode and the I, cathode from a minimum to a maximum by merely shifting the phase of the grid potential relatively to the anode potential. l Fig. shows a vector diagram representing how the grid potential is shifted relative to the anode potential.

The vector K O represents-the potential between the terminal 2| and the mid-tap .I5 or the secondary transformer I6, and the` vector ON represents the potential between vthe midtap IB and the terminal 22 -oi the secondary transformer I3. Since the anodes 28 and 32 of the power grid-glow tubes are connected in circuit relation with the secondary transformer winding I8, the phase relation of the anode pctential oi the power grid-glow tubes is always in phase with the vectors K0 and ON. The tential across the capacitor 31. is represented enerally by the length of the vector KP.v when the slidably mounted core 39 is totally removed from the control winding 38, the potential Vacross the control winding 38, resulting from the reactance only, is represented by the llength of the vector PR. The potential caused by the effective resistance of thev control winding 38 is represent- In the practice ci my invention. I prefer toas the description advances, it will be seen that. although my method oi.' control is primarily the phase-shifting method, it still partakes ofthe magnitude" method, thus resilltlnsin' a combination of the two.

The bridge circuit. I3 for shifting the phase and,

control winding 38 having a slidably mountedparallel circuit relation, the phase relation and g l anode and the cathode. Referring particularly v;. to Figs. 2 and 3, the higher substantially sinusoidal` shaped curve represents the critical grid potential. :i

the remaining part of the half cycle. In Figs..v

ments. Hence, it is possible to vary the quantity ed by the length of the vector RN, making the potential resulting from the total impedance of the control winding equal to the vector PN. Hence, thev phase relation of the grid potential relative to the anode potential is represented by the angle PON, while the length of the vector OP represents the magnitude of the grid potential. Therefore, when the slidably mounted iron core 39 is totally retracted from the control winding 38, by means of the illustrated rack and pinion control knob 40, the phase relation between the grid potential and the anode potential is relatively small, with the result that the power grid-glow `tubes pass current during substantially the entire half cycle, as represented generally by the shaded portion in Fig. 2.

As the slidably mounted magnetic core 39 is gradually moved into the control winding 38, the impedance thereof correspondingly increases, causing a shifting of the phase of the grid potential with respect to the anode potential. When the slidably mounted magnetic core 39 is fully inserted within the control winding 38, the potential, resulting from the reactance only, greatly increases, thus causing the grid vector OP to swing in a clockwise direction to OP. Hence, the phase relation of the grid potential with respect to the anode potential is represented by the angle P'ON, while the magnitude of the ,grid potential is represented by the length of the vector OP'. In this position, the vector P'R' represents the potential of the control winding 38 caused by the reactance only. The potential resulting from the eiiective resistance of the winding 38, since it gradually increases as the slidably mounted core 39 is moved into the control winding 38 because of the increased iron losses, is represented by the vector RN, making the total potential resulting from the impedance of the control winding 38 equal to the length of the vector NP.

By sliding the magnetic core 39 in-and-out of the control winding 38, the quantity of current which the grid glow tubes pass varies from a minimum as represented in Fig. 3 to a maximum as represented in Fig. 2. c

The dotted lines above the vectors KO and ON represent the magnitude and the phase relation of the grid potential during the other half cycle.

In starting the motor I0, assuming that the primary transformer winding I2 is energized by the supply conductors 5I and 52, the operator depresses the push button 44, which establishes a circuit for actuating the winding of the relay 43. This circuit may be traced from the midpoint of the asymmetric units 4| 'and 42, which is of a positive potential, through a conductor 55, the push buttons 44 and 45, conductor 59, the winding of the relay 43, and conductor 60 to the mid-tap 54 of the secondary transformer winding I8 which is of a negative potential with reference to the mid-point of the asymmetric units 4I and 42. The closing of the lower contacts J of the relay 43, established a holding circuit through the conductors 6| and 62, for relay 43, although the push button 44 may be released. When the relay 43 is energized, current flows during the positive half of the cycle from the terminal 53 of the secondary transformer I8, through a conductor 63, the uppermost contacts .of the relay 43, conductor 69, the anode and the cathode of the power grid-glow tube 3|, conductor 6l, the armature of the motor I0, and

conductors 56 and 60 to the mld-tap 54 of the transformer winding I8.

During the positive half cycle, the power gridglow tube 21 is inoperative because a grid-glow tube passes current only when both the anode and the grid are of a positive potential. On the next half or negative portion of the cycle, since the anode 28 is positive and the grid 29 is posi-L tive, the grid-glow tube 2`I is operative and current flows from the terminal 55 of the secondary transformer I8 through conductors 46 and 68, the middle contacts of the relay 43, the anode 28 and the cathode 30 of theI power grid-glow tube 21, conductor 61, the armature of the motor I0, and conductors 56 and 68 to the mid-tap 54. During the negative half cycle, the power gridglow tube 3| is inoperative and passes no current because the potentialy of the anode 32 .and the grid 33 are both negative. Therefore, by means of my improved bridge phase-shifting circuit |3, the speed of the motor may be varied from a minimum to a maximum, depending upon the quantity of current passed by the power gridglow tubes.

In the embodiment of my control system, it is readily apparent that the starting and stopping of the motor I0 could be effected by energizing and deenergizing the primary of the transformer 9, in which case the relay 43 could be omitted.

However, I have illustrated the relay 43 because I the life of the power grid-glow tubes is materially extended when the hot cathodes are allowed to heat up before the anode potential is applied by closing the contacts of the relay 43. Although I have illustrated the slidably mounted magnetic core 39 operated by a rackand pinion control knob 40, it may readily be actuated by means of a foot treadle so that the operator may vary the speed by merely varying the relative positions of the foot. The control winding 38 may be economically manufactured because it comprises nothing more than a winding having a plurality of turns upon a spool of suitable size.

In Fig. 5, I illustrate a control circuit .embodying substantially all of the parts of the control circuit in Fig. l, and like reference characters represent like parts, together with ancillary circuits to automatically and gradually accelerate the motor I 0 from rest to any predetermined selected speed. In this embodiment of the invention the effectiveness of the control winding 38 is changed by means of an ancillary winding 86 connected in closed circuit relation with a three-electrode vacuum tube |00 having a plate |0I, a filament |03 heated from the extra transformer secondary winding |04, and a grid |02. For the purpose of providing an effective coupling between the ancillary winding 86 and control winding 38 an irony core 89 is provided. The potential across the control winding 38 may be varied from a minimum value to a maximum value by causing the three-electrode vacuum tube to vary the impedance of the closed circuit. As is well known inthe art, if the grid |02 is charged sufflcientlynegative, the impedance of the vacuuxn tube |00 is relatively high, representing the open condition of the closed circuit, whereas, cn the contrary, if the potential of the grid |02 is charged sunlciently positive, the impedance of the vacuum tube |00 is relatively low, representing closed circuit condition.

Although several systems are available for gradually varying the potential of the grid |02 relative to the filament |03, I prefer to util'ze a capacitor |i0, in combination with resistors H2, I I3 and I Il. The combination of the reactor I I6, and the two capacitors ||4 and H5, is employed as a filter for providing a substantially constant flow of unidirectional current. By means of the filtering action, smoother operation of the control system is obtained.

` In starting the motor I shown in Fig. 5, the push-button 44 is closed iirst, which, in turn, cnergizes the relay 43 for connecting the power grid-glow tubes 21 and 3| in circuit relation with the armature of the motor I0 and the secondary winding I8. In the. usual operation, the relay 43, generally, .remains in the closed position for the entire working day or for the performance of a particular piece of work.

After the power grid-glow tubes 2`|y and 3| are connected in circuit relation with the armature i0 and the secondary winding I8, the operator next operatesthe push button IIS, which establishes a circuit for energizing the relay |05. This circuit may be traced from the positively energized conductor 55, through the push buttons I I9 and |20, conductor |3|, the winding of the relay |05, conductor |32, contacts of the relay 43, and conductor |33 to thenegatively energized conductor |34. By reason of the fact that this circuit is carried through the contacts of the relay 43, itis necessary that the relay 43 be closed before the relay |05 can;be energized. However, be-

fore the operator operates the push-button H0,

- it will be observed thatl the condenser ||0 is shunted and that the potentialof the grid |02 of the vacuum tube |00 is therefore charged negatively with respect to the cathode |03. The cir-r ,cuit for charging the grid |02 `at a negative potential may be tracedfrom the negatively energized conductor |34 through the right-hand portion of '-theadjustable resistor I Il, conducto-r |38, the reactor I I0, the contacts of the relay I I8, conductor4 |39, the'lowermost contacts |09 of the relay |05, conductor |39 to the grid |02. The

cathode |03 of the vacuum tube |00 is alwaysmaintained at a postive potential because the conductor |22 that leads to the cathode |03 is connected to the positively energized conductor 55. Therefore, before the start push-button H0 is depressed, by reason of the fact that the grid |02 is charged negatively with respect to the cathc-de, the eiective impedance of the vacuum tube |00 is relatively high, representing substantially an open circut condition of the closed winding that comprises the ancillary winding 80. This means that the potential across the control winding 38 is a maximum, with the result that the power grid-glow tubes 21 and 3| pass insuicient current to cause the motor I0 to run.

Just as soon as the push button 9 is depressed, the' shunt across the condenser ||0 is removed and, as a result, the condenser gradually bulds up to a potential as determined by the setting'of the adjustableresistor I3. The charg -ing circuit for the`condenser ||0 may be traced from the negatively energized conductor |34, through the right-hand portion of the adjustable resistor the conductor |38, the reactor H8,

resistor ||3 to the positively energized conductor 55. The condenser gradually builds up, at the same time, causing the potential of the grid |02 to change from av negative value to a positive value. This means that the eiective impedance `at any predetermined selected value.

of the vacuum tube |00 is, accordingly, changed and gradually varies the impedance of the control winding 38. By the gradual change of the impedance o! the control winding 38, the power grid-glow tubes pass an increasing amount of current from a minimum value to a maximum value, thereby accelerating the motor from rest to any predetermined selected speed.- By varying the settings of the adjustable rheostat I3, the potential, at which the condenser becomes charged, may be varied. That is to say, as the settings of the adjustable resistor ||3,is moved towards the positively energized conductor 55', the potential of the condenser gradually approaches the potential of thepositively energized conductor. Therefore, by varying the setting of the adjustable rheostat I|3, the speed of the motor may be set Also, by means of the adjustable resistor l, the rate at which the condenser builds up, may be varied, and, hence, the operator is able to vary the rate the push button H0. By depressing the push button I2 I ,current flows from the positively energized conductor 55 through conductor |42, push button |2|, conductor |43, the winding of the relay to the negatively energized conductor |34. The opening of the contacts of the relay ||8 disconnects the capacitor ||0 from the grid circuit of the vacuum tube and directly convnects the grid |02 in circuit relation 'with the adjustable resistor ||2 through the contacts |08 of the relayv |05.` This momentarily biases the potential of the grid |02 of the vacuum tube |00 to a potential determined by the setting of the adjustable resistor ||2. The nearer the setting of the adjustable resistor ||2 approaches the positively energized conductor 55, the closer the potential of the grid |02 approaches the potential of the cathode |03. Therefore, the impedanceof the control winding 3 8 is momentarily decreased to a minimum value for causing the power gridglow tubes to momentarily pass a relatively large quantity of current to the motor I0 for producing al very high starting torque to overcome the high inertia load to which the motor is connected. After the motor has once set the high inertia load in rotation, the operator removes his iinger from the push button |2| and depresses th'e start button I9, and the motor gradually accelerates to the predetermined selected speed value as deterr'risned by the setting of the adjustable resistor Fig. 6, a modied formV of my invention, shows a means for varying the impedance of the control winding 38 in accordance with the tension of material being wound upon a reel. 'I'he motor I0 and thecontrol winding 38 of Fig. 6 are the same as those shown. in Fig. l. The remaining -,control circuit of Fig. 6 is not shown because it is exactly the same as the control circuit of Fig. 1. illustrated, in Fig. 6, the reel 80 is driven by vthe motor I0 and is withdrawing material from y.the supply reel 8|. Bymeans vof the two stationary guide rollers 82 and 83 and the movable guide roller 84, the magnetic core 85 o1' the control .winding 88 may be moved in accordance with the tension of the material being wound. If the causes the power grid-glow tubes to pass a sub-p` tension increases, the magnetic core is raised into the control winding 38, with the result that the quantity of current passing through the power grid-glow tubes 21 and 3| is decreased for lowering the speed of the motor. On the contrary, if the tension of the material becomes less than a predetermined value, the magnetic core is lower and the quantity of current passing through the power grid-glow tubes is increased for increasing the speed of the motor t0. By means of this arrangement, the tension at which the material is being wound is maintained at a substantially constant value.

Associated with the control winding 38 of Fig. 6, I employ an ancillary Winding 86 connected in closed circuit with an adjustable resistor 81. This closed circuit is comparable to the closed circuit shown in Fig. 5, but the push button 88 and the adjustable resistor 81 replace the action of the vacuum tube 00. The closed circuit is designed to give a very large starting torque for starting the motor l0 when it is connected to high inertia load. By merely depressing the push button 88, the impedance of .the control winding 38 is greatly lowered, which, in turn,

stantially maximum quantity of current for causingthe motor l0 to develop a high starting torque. The value of the high starting torque may be adjusted by varying the settings of the adjustable resistor 81.

Although I have illustrated my invention with power grid-glow tubes wherein the cathode is a lament, it is toy be understood that power gridglow tubes of other types may be utilized, such for example as, the equally welliknown tubes employing a mercury pool for the cathode. The

critical grid potential characteristics of this lastnamed tube are somewhat different from those given by the characteristic curves in Figs. 2 and 3, but the results accomplished by using either type of tubes may be substantially the same.

Therefore, my control system, with its modified forms, provides for controlling a motor to meet any desirable operating conditions for which the motor may be utilized.

Since certain changes in my invention maybe made without departing from the spirit and scope thereof, it is intended that all matters contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

I claim as my invention:

A motor starting control system comprising, in combination, an electric motor driving a load, means for energizing the motor, an electric discharge device for controlling the energization of the motor, a bridging circuit for regulating the velectric discharge device, said bridging circuit in- JOSEPH F. KOVALSKY. 

